SCAFFOLD APPARATUS, METHOD AND SYSTEM
Scaffold components and system for coupling a horizontal member to a vertical member of a scaffold, comprising a horizontal member and a wedge head attached to each end of the horizontal member each wedge head having an associated wedge assembly.
Latest Next Generation Scaffold Services Inc. Patents:
This application claims priority to U.S. Provisional Application No. 61/461,938 filed on Jan. 25, 2011, entitled “SCAFFOLD SYSTEM”.
FIELD OF THE INVENTIONThis invention relates to modular scaffolding systems that are erected as impermanent structures to support platforms. Scaffolding is used, inter alia, in the industrial, commercial, petro-chemical, power source, general industry and residential construction markets.
BACKGROUNDIn 2008, the Bureau of Labor Statistics' Census of Fatal Occupational Injuries (CFOI) reported 88 fatalities occurred in the year 2007 related to the use of scaffolds and many more injuries. Twenty-seven percent (27%) of the fatalities and many of the injuries involved falls off of welded frame scaffolds over 25 feet high during the installation of the scaffolds. Safety officials recommend that scaffolding falls be pre-empted through the use of sequential erection techniques. This involves installing guardrails and standards at regular distances along the scaffold such that the exposed platform edge is not greater than a bay length between intervals. The use of safety harnesses or belts tethered to guardrails during the erection process is also a recommended safety practice. However, the use of safety harnesses to deter fall injuries during scaffold erection is quite limited due to the components used in conventional scaffolds. The nature and design of conventional scaffold components, as described herein, disadvantageously do not allow the effective use of safety harnesses during the erection process.
Tube and coupler scaffolds are so-named because they are built from tubing connected by coupling devices. Due to their strength, they are frequently used where heavy loads need to be carried, or where multiple platforms must reach several stories high. Components of scaffolds include vertical standards having coupling rings or rosettes, horizontal components such as ledgers and guardrails coupled to the coupling rings or rosettes, footings, decks/platforms and diagonal braces. Their versatility, which enables them to be assembled in multiple directions in a variety of settings, also makes them difficult to build correctly.
Conventional scaffolding systems have various components.
Referring now to
A conventional rosette 500, as seen in
What is desired is a scaffolding apparatus that is configured to couple each end of a ledger (also referred to herein as a horizontal member) to a vertical standard (also referred to herein as a vertical member) simultaneously, and which has an wedge assembly mechanism that allows a single installer to insert and lock wedges at both ends of the horizontal member substantially simultaneously to the vertical standard. The invention provides such an apparatus.
SUMMARYThe invention comprises a scaffold apparatus that overcomes the safety, rigidity, and labor issues inherent in conventional scaffold systems. The ring, collar, rosette or component with similar functionality, is referred to as a rosette with respect to the invention; the vertical standard or component with similar functionality, is referred to as a vertical member with respect to the invention and the ledger, guardrail or component with similar functionality is referred to as a horizontal member. The use of the foregoing terms is not to be interpreted as limiting the scope of the invention.
As noted herein, components of the invention include at least one horizontal member and a wedge head attached to each end of the horizontal member. A wedge assembly is located partially within the horizontal member and each wedge head, each wedge assembly having a handle coupled to a wedge portion for coupling the wedge head to a vertical member.
A rosette having a set of radially arranged cut-outs, the vertical member affixed in coaxial alignment with the rosette, is provided to receive the wedge head having mating elements corresponding to the radially arranged cut-outs of the rosette, wherein, when the mating elements of the wedge head are received in the radially arranged cut-outs of the rosette, the wedge assembly, when actuated, causes the wedge portion to rigidly couple the horizontal member to the rosette. The handle of the wedge assembly is springably coupled to the wedge head, said handle, when actuated, being operable to cause the wedge portion to partially extend or retract into the wedge head. A rod or cable within the horizontal member, couples the first handle of the wedge assembly to the second handle at the other end of the horizontal member, causing it to simultaneously engage or disengage the wedge at the other end of the horizontal member.
Each of the wedge heads have at least one or a plurality of mating elements or prongs dimensioned to fit within a grid of apertures formed in the rosette, the wedge head having an opening or slot through which the wedge portion wholly or partially extends to lock the wedge head, and hence, the horizontal member to the rosette and wholly or partially retracts to unlock the wedge head, and hence, the horizontal member from the rosette.
To those skilled in the art to which this invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined herein and in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
A more complete understanding of the invention may be obtained by reference to the following Detailed Description, when taken in conjunction with the accompanying Drawings, wherein:
The invention comprises a scaffold system, and components thereof, that overcomes the safety, rigidity, and labor issues inherent in conventional scaffold systems. The ring, collar, rosette or component with similar functionality, is referred to as a rosette with respect to the invention; the vertical standard or component with similar functionality, is referred to as a vertical member with respect to the invention and the ledger, guardrail or component with similar functionality is referred to as a horizontal member. The use of the foregoing terms is not to be interpreted as limiting the scope of the invention.
As noted herein, components of the invention include at least one horizontal member which horizontal member preferably has a wedge head at each end thereof, alone or in combination with at least one vertical member including at least one rosette affixed in coaxial alignment thereon, the rosette having apertures for receiving mating elements or prongs of an wedge head (which may be a separate component of the horizontal member, or an integrated portion at the end of the horizontal member), a wedge assembly within the wedge head and horizontal member, the wedge assembly having a separate handle and wedge portion or integrated handle and wedge portion, the wedge assembly at an end of the horizontal member being responsively coupled to a wedge assembly at the other end of a horizontal member using a rod or cable or other transmission means. Each wedge head may further include one or a plurality of prongs dimensioned to fit within a grid of apertures formed in the rosette. The wedge head has an opening or slot through which the wedge portion extends wholly or partially out of the wedge head to lock the wedge head when activated by a handle, operable to couple the horizontal member to the rosette
An aspect of the invention is a joint for use in coupling a horizontal member to a vertical member having a rosette with a set of radially arranged cut-outs, a horizontal member further comprising a hollow tube having contained therein a wedge assembly, the wedge assembly having a wedge portion at the end thereof which is wholly or partially extendable and retractable into a hollow tube or cavity of a wedge head and/or horizontal member. The wedge head, located at the end of the horizontal member, has mating elements corresponding to the radially arranged cut-outs of the rosette. When the mating elements of the wedge head or the horizontal member are received in the radially arranged cut-outs of the rosette and the wedge assembly is actuated using, e.g., a handle, causes the wedge portion to firmly join or couple the wedge head or horizontal member to the rosette.
Referring now to
A first extension on which pressure is applied by a user to lock or unlock the invention to a rosette is handle 812. An integrated offset angled extension from handle 812 is the handle linkage assembly 806. The handle linkage assembly 806 has a plurality of apertures for coupling to components such as the wedge and rod and to wedge head 802. Handle 812 and handle linkage assembly 806 are rotatably coupled to wedge head 802 with pin 805 and are movable along an arc of motion via guide 813 and pin 807. The first end of rod 809 is rotatably coupled to handle linkage assembly 806 with pin 811. The second end (not seen) of rod 809 is coupled to a second wedge at the distal end of horizontal member 810.
In a second embodiment as more fully described below, rod 809 and its related mechanisms are replaced with a cable which couples a first handle linkage assembly in a wedge head at one end of a horizontal member to a wedge head at a second end of the horizontal member. The tension of the cable operates to bias the wedges at each end of the horizontal member simultaneously in either the extended (locked) or retracted (unlocked) position depending on the position of their respective handles. As noted below, the cable can be threaded around internal pins, wheels and axles and biased with, inter alia, springs.
In operation, the wedge head 802 is at one end of the horizontal member 810. The wedge head 802 has handle 812 pivotably coupled to the wedge head 802 with the end of the handle 812 internal to the wedge head 802 being integrated at a first end to the handle linkage assembly 806. The handle linkage assembly 806 is pivotably coupled to the wedge head 802, a distal end of a wedge 818 being rotatably coupled with a pin 808 or similar mechanism to the handle linkage assembly 806 at a mid-section thereof. The wedge 818 is biased by a transverse portion of spring 803 causing the wedge 818 to press down against the face of a rosette when the wedge 818 is extended by the handle 802. The first end of a rod 809 is coupled via a pin 811 or similar mechanism at a second end of the handle linkage assembly 806 and the second end (not shown) of the rod is coupled to a second wedge (not shown) for extension and retraction at the distal end of the horizontal member. The coupling of the rod 809 and wedge 818 to the handle linkage assembly at the distal end of the horizontal member are coupled via a rotatable cam mechanism as seen in
More specifically, first handle 1103 is dimensioned as a substantially horizontal handle grip extension 1103A having a substantially vertical wedge 1103B extending in a substantially orthogonal direction due to an incurvature from the horizontal handle grip extension 1103A. Cable linkage assembly 1103C is located proximate the bottom of the vertical lock extension 1103B and serves as an anchor point from first handle 1103 to first end 1101B of cable 1101.
Second handle 1104 is dimensioned as a substantially horizontal handle grip extension 1104A having a substantially vertical wedge 1104B extending in a substantially orthogonal direction due to an incurvature from the horizontal handle grip extension 1104A. Cable linkage assembly 1104C is located on the bottom of the horizontal handle grip extension 1104A between the end of the horizontal handle grip extension 1104A and the point of curvature from the horizontal handle grip extension 1104A to vertical wedge 1104B and serves as an anchor point from second handle 1104 to second end 1101A of cable 1101.
First handle 1103 has an aperture 1103D located proximate the point of curvature between the horizontal handle grip extension 1103A and the vertical wedge 1103B, said aperture 1103D to axially receive a pin, rivet, screw or other similar structure through the first handle 1103 so as to rotatably couple the first handle 1103 through the walls of the first wedge head 1105. The coupler, can include, but is not limited to a bolt and a nut, rivet, revolute, pin and associated washers, bushings and/or bearings, each coupler being part of linkage assembly.
Second handle 1104 has an aperture 1104D located proximate the point of curvature between the horizontal handle grip extension 1104A and the vertical wedge 1104B to axially receive a pin, rivet, screw or other similar structure through the second handle 1104 so as to rotatably couple the second handle 1104 through the walls of the second wedge head 1106. The coupler, can include, but is not limited to a bolt and a nut, rivet, revolute, pin and associated washers, bushings and/or bearings, each coupler being part of linkage assembly.
The tension of the cable 1101 operates to bias the wedge portions 1103B, 1104B at each end of the horizontal member simultaneously in either the locked or unlocked position depending on the position of their respective handles. The cable can be threaded around internal pins, wheels and axles and biased with springs. By actuating either of handle 1103 or 1104, wedge portions 1103B, 1104B (respectively), can be simultaneously retracted or extended into the housing portions of wedge heads 1105, 1106, respectively. Upward facing teeth 1103E, 1104E, are integrated into the bottom of wedge heads 1105, 1106 to receive rosette apertures when the wedge portions 1103B, 1104B are in the unlocked positions, that being when the first handle 1103 and second handle 1104 are in the upper position. After the rosettes are positioned within the teeth 1103E, 1104E (of which there may be a plurality integrated on the wedge heads 1105, 1006), force can be applied to either the first handle 1103 or second handle 1104, which will cause both associated wedge portions 1103B, 1104B, respectively, to move into the locked position. This simultaneous locking effect is accomplished by the action of the cable 1101 working in concert with the applied force of springs 1110, 1111.
First handle 1103 and second handle 1104, and associated wedge portions 1103B, 1104B are each springably biased into certain positions (extended (locked) or retracted (unlocked)) via springs 1110, 1111 which are coupled via pins, axles or similar structure, to wedge heads 1105, 1106.
Referring to
Referring to
The embodiments further include being in combination with at least one rosette attached, e.g., welded, to each vertical member. Each vertical member may have a plurality of evenly or unevenly spaced rosettes affixed, e.g., by weld, along a vertical member. The rosette has a pattern or grid of apertures designed to receive the mating elements, such as prongs at the end of a horizontal member. A wedge head may be located at the end of the horizontal member. The horizontal member is a hollow tube, preferably cylindrical in shape, having a first end and a second end. At the first end and the second end may be fixedly attached, a wedge head, as more fully described herein.
The invention further includes the method for coupling a horizontal member to a vertical member of a scaffold, comprising providing a horizontal member having a wedge head coupled to each end of the horizontal member, the wedge heads each having therein a wedge assembly partially within the wedge head, each wedge assembly pivotably coupled to its respective wedge head, each wedge assembly further comprising a handle communicably coupled via a wedge linkage assembly to a wedge, the wedge linkage assemblies being operatively coupled via a cam mechanism within the horizontal member; and disengaging either handle causing each wedge to simultaneously, partially retract into its respective wedge head. The method further includes the step of placing each wedge head on a corresponding rosette of a vertical member and engaging one of the handles so as to cause each wedge to lock the ends of the horizontal member simultaneously to the vertical members.
In an embodiment of the invention, the design of the wedge head at each end of each horizontal member keeps scaffold components square and ridged at all times utilizing predetermined angles via the grid design. The scaffold design of the invention reduces leading edge fall hazards associated with conventional scaffold systems. The scaffold design of the invention also reduces the need for hand tools during the installation and dismantling of horizontal members. Advantageously, the scaffold design of the invention reduces the amount of labor and time needed to install and dismantle a scaffold system.
The components of the invention can be fabricated from a variety of materials, including galvanized or powder coated steel, iron or other resilient material. The rosette preferably has a seven inch (7″) diameter, and the internal first and second rods can comprise two square, or cylindrical rods, made of e.g., steel or iron, each having a wedge shaped wedge portion added or integrated at an end, the opposite ends being coupled to the crank/cam assembly. Using the grid pattern of apertures on the rosette and head having prongs dimensioned to fit therein, various angles between the horizontal members can be obtained (e.g., 45, 90, 180 degrees) for the elevated working platform.
Advantageously, the invention allows the erector to engage and disengage both wedge portions of a single horizontal member from a single point reducing installation time and creating a safer work environment. This is because the only one of the handles between the first end and the second end of the horizontal member need be actuated to engage and disengage each wedge substantially simultaneously. In this manner, up to eight (8) horizontal members can be attached to a single vertical member by a single installer without changing his position.
The invention further comprises a grid of components that mesh together creating rigid angled connection among a plurality of horizontal members at a vertical member. Both of the wedges which are part of a wedge assembly, are locked into position at the rosette on a vertical member from a single position. The internal wedge portions are locked into place by an external handle eliminating the use of any hand tools. The external handle can also be locked into place creating a secondary locking device.
The embodiments shown and described above are only exemplary. Even though numerous characteristics and advantages of embodiments of the invention have been set forth in the foregoing description together with details of the invention, the disclosure is illustrative only and changes may be made within the principles of the invention to the full extent indicated by the broad general meaning of the terms used herein. For example, the concepts described herein for coupling horizontal members to vertical members can be used to couple bracing members to vertical members or to horizontal members. Coupling includes, but is not limited to attaching, engaging, mounting, clamping, welding, bolting and components used for coupling include bolts and nuts, rivets, clevis, latches, clamps, welds, screws, rivets and the like. Further, a rosette having eight (8) radially arranged cut-outs is described herein for illustrative purposes and a rosette having more or less radially arranged cut-outs is considered to be within the scope of this invention. Also, the invention describes a rosette having a standard diameter of about seven (7) inches, however, any suitable diameter can be used. The use of a wedge head with a pair, or a wedge head with two pair, of vertical prongs is described herein for illustrative purposes and a wedge head having one or more prongs is considered within the scope of this invention. The rosette can include any suitable cut-out shape that is dimensioned to receive a corresponding prong or set of prongs of a wedge head. The vertical member can have any number of coaxially aligned rosettes attached thereto, the vertical spacing of such rosettes being any such distance as is suitable for the intended use. More generally, the invention is a scaffold system with a horizontal member, a vertical member with at least one rosette affixed in coaxial alignment to the vertical member and a wedge assembly within the horizontal member, portions of the wedge assembly for locking the horizontal member to the rosette. The vertical member has a plurality of evenly spaced rosettes affixed in coaxial alignment along the vertical member and at least one rosette has a pattern or grid of apertures designed to receive the end of the horizontal member.
Claims
1. An apparatus for coupling a horizontal member to a vertical member of a scaffold, comprising:
- a horizontal member and a first wedge head coupled to a first end of the horizontal member; and
- a first wedge assembly partially within the first wedge head, the first wedge assembly pivotably coupled to the first wedge head, the first wedge assembly further comprising a first handle communicably coupled via a first wedge linkage assembly to a first wedge.
2. The apparatus of claim 1, further comprising the first handle of the first wedge assembly further being springably coupled to the first wedge head, said first handle, when actuated, operable to cause the first wedge to fully or partially extend or retract into the first wedge head.
3. The apparatus of claim 2, further comprising a second wedge head coupled to a second end of the horizontal member; and
- a second wedge assembly partially within the second wedge head, the second wedge assembly pivotably coupled to the second wedge head, the second wedge assembly further comprising a second handle communicably coupled via a second wedge linkage assembly to a second wedge.
4. The apparatus of claim 3, further comprising the second handle of the second wedge assembly further being springably coupled to the second wedge head, said second handle, when actuated, operable to cause the second wedge to fully or partially extend or retract into the second wedge head.
5. The apparatus of claim 4, further comprising a cam mechanism and a first rod within the horizontal member, the first end of the first rod rotatably coupled to the first handle via the first wedge assembly and the second end of the first rod pivotably coupled to a first end of the cam mechanism within the horizontal member, the center of the cam mechanism being rotatably coupled to the horizontal member.
6. The apparatus of claim 5, further comprising a second rod within the horizontal member, the first end of the second rod rotatably coupled to the second handle via the second wedge assembly and the second end of the second rod pivotably coupled to the second end of a cam mechanism within the horizontal member.
7. The apparatus of claim 6, the first handle operatively coupled to the first wedge and first rod and second handle coupled to the second wedge and second rod, the first rod being operatively coupled to the second rod via the cam mechanism, such that when the first handle is moved, the second handle simultaneously moves in correspondence, such that the first wedge and the second wedge extend or retract simultaneously.
8. The apparatus of claim 1, in combination with a rosette having a set of radially arranged cut-outs, the rosette affixed in coaxial alignment with a vertical member.
9. The apparatus of claim 8, wherein each wedge head has mating elements corresponding to the radially arranged cut-outs of the rosette, wherein, when the mating elements of the wedge head are received in the radially arranged cut-outs of the rosette, the wedge assembly, when actuated, causes the wedge to rigidly couple the horizontal member to the rosette.
10. An apparatus for coupling a horizontal member to a vertical member of a scaffold, comprising:
- a horizontal member and a first wedge head coupled to a first end of the horizontal member;
- a first wedge assembly partially within the first wedge head, the first wedge assembly pivotably coupled to, and biased with reference to the first wedge head, the first wedge assembly further comprising a first handle and a first wedge;
- a second wedge head coupled to a second end of the horizontal member;
- a second wedge assembly partially within the second wedge head, the second wedge assembly pivotably coupled to, and biased with reference to the second wedge head, the second wedge assembly further comprising a second handle and a second wedge; and
- the first handle of the first wedge assembly or the second handle of the second wedge assembly, when either are actuated, being operable to cause both of the first wedge and second wedge to fully or partially extend or retract, simultaneously.
11. The apparatus of claim 10, further comprising a cable having a first end and a second end coupling the first handle and linkage assembly of the first wedge head at one end of the horizontal member to the second handle at the second wedge head via pulley at a second end of the horizontal member.
12. The apparatus of claim 11, wherein the first wedge head serves as a housing around portions of the first handle and the second wedge head serves as a housing around portions of the second handle.
13. The apparatus of claim 10, wherein the first handle is dimensioned as a substantially horizontal handle grip extension having a substantially vertical wedge extending in a substantially orthogonal direction due to an incurvature from the horizontal handle grip extension and wherein a cable linkage assembly is located proximate the bottom of the vertical lock extension and serves as an anchor point from the first handle to first end of the cable.
14. The apparatus of claim 13, wherein the second handle is dimensioned as a substantially horizontal handle grip extension having a substantially vertical wedge extending in a substantially orthogonal direction due to an incurvature from the horizontal handle grip extension and wherein cable linkage assembly is located on the bottom of the horizontal handle grip extension between the end of the horizontal handle grip extension and the point of curvature from the horizontal handle grip extension to the vertical wedge and serves as an anchor point from second handle to second end of the cable.
15. The apparatus of claim 14, wherein first handle has an aperture located proximate the point of curvature between the horizontal handle grip extension and the vertical wedge, said aperture configured to axially receive a pin, rivet, screw or other similar structure through the first handle so as to rotatably couple the first handle through the walls of the first wedge head; and
- the second handle has an aperture located proximate the point of curvature between the horizontal handle grip extension and the vertical wedge to axially receive a pin, rivet, screw or other similar structure through the second handle so as to rotatably couple the second handle through the walls of the second wedge head.
16. The apparatus of claim 15, wherein the tension of the cable operates to bias the wedge portions at each end of the horizontal member simultaneously in either the extended or retracted position depending on the position of their respective handles.
17. The apparatus of claim 10, in combination with a rosette having a set of radially arranged cut-outs, the rosette affixed in coaxial alignment with a vertical member.
18. The apparatus of claim 17, wherein each wedge head has mating elements corresponding to the radially arranged cut-outs of the rosette, wherein, when the mating elements of the wedge head are received in the radially arranged cut-outs of the rosette, the wedge assembly, when actuated, causes the wedge to rigidly couple the horizontal member to the rosette.
19. A method for coupling a horizontal member to a vertical member of a scaffold, comprising the steps of:
- providing a horizontal member having a wedge head coupled to each end of the horizontal member, the wedge heads each having therein a wedge assembly partially within the wedge head, each wedge assembly pivotably coupled to its respective wedge head, each wedge assembly further comprising a handle communicably coupled via a wedge linkage assembly to a wedge, the wedge linkage assemblies being operatively coupled via a cam mechanism within the horizontal member; and
- disengaging either handle causing each wedge to simultaneously, partially retract into its respective wedge head.
20. The method of claim 19, further comprising the step of placing each wedge head on a corresponding rosette of a vertical member and engaging one of the handles so as to cause each wedge to lock the ends of the horizontal member simultaneously to the vertical members.
Type: Application
Filed: Jan 12, 2012
Publication Date: Jul 26, 2012
Applicant: Next Generation Scaffold Services Inc. (Las Vegas, NV)
Inventors: Steve Howard Thacker (The Woodlands, TX), Johnny Russel Curtis (Denham Springs, LA), Yates Wesley Hayman (Brookhaven, MS)
Application Number: 13/349,482
International Classification: E04G 7/32 (20060101); E04G 21/14 (20060101);